Removing Fuel Tank

REMOVING AND INSTALLING FUEL TANK FROM M1992






WARNING Ensure good ventilation. If approved ventilation for removal of fuel fumes is available, this should be used.

Wear protective gloves. Long-term contact with fuel can cause skin irritation.

Keep a class BE fire extinguisher nearby. Be careful of the danger of sparking, e.g.from circuit breaking, short circuiting etc.

No smoking.

Removal:

1. Empty the fuel from the tank.

2. Remove the two retaining screws from the floor of the luggage compartment and remove the floor.

3. Turn both the bayonet fasteners that secure the cover over the fuel pump using a hexagon key and remove the cover.

4. Detach the fuel line and the electrical connections to the fuel pump.






5. Clean around the filler pipe and its connections.

6. Remove the hose clips on the breather hose and at the lower rubber elbow.

7. Tuck the rubber elbow and breather hose to one side.

8. Remove the handbrake cable from the lever as well as the rubber fastener for the cable from the spring.

9. Undo the nuts on the tank strap. Start with the strap on the RH side and bend the handbrake cable to one side. Lift down the strap on the LH side. Support the tank while working.

10. Lift down the tank LH side first. Make sure that the tank's pipe is not damaged against the plate edge of the bodywork.

Fitting:

Tightening torque for hose clips: 2 Nm (16 ft. lbs.).


Important
Danger of cracking if they are over-tightened.

Fit the anti-splash device (butterfly valve) so that the butterfly spindle is vertical.



Important
The strap fastener must not turn as the bolt is tightened as it is likely to shear at the weld.

After fitting and tightening, the strap must be straight.

Otherwise fit in reverse order.